Deployment

Putting Augos in doesn't touch your PLC or stop your line. One sensor and one terminal go onto the line, you need a 220 V point, 4G is built in, and the rules arrive over the air. A line is live within 48 hours of the kit arriving, and the same kit rolls out across lines, sites, regions and languages.

Live within 48 hours

One pulse sensor mounts onto the line and the Augos Operator Terminal, the industrial touchscreen computer where operators record every stop, is installed where the operator works. The terminal is the brain of the line: it does all the counting, stop detection and timing itself and keeps working without a network; the connection is needed only to sync to the platform and to receive your rules over the air. The site supplies a 220 V point. The terminal has 4G built in and Augos supplies a data SIM at no cost, so no plant network is needed; Ethernet or Wi-Fi work too, with your IT team's sign-off. The site assessment doesn't need a visit: videos, photographs and a line layout from someone on site are enough to confirm where the terminal and sensor go. Because configuration is applied over the air, installation can begin before the plant's products, stoppage reasons and operators have been finalised, and those rules change over the air whenever the plant does. A line is live within 48 hours of the kit arriving; operators train next.

Nothing is wired into your PLC, MES or CMMS: one sensor and one terminal are the whole installation. That removes the PLC tags, the integrator and the ongoing maintenance that make other OEE deployments slow. If you want planned jobs from your ERP on the terminal, the Augos API carries them. The data stays rich because the operator records the reason for every stop at the terminal, including the reasons no sensor could see.

What installing a line involves

Before installation you complete three templates: a Product template (each product's rated speed, pulse factor, pack size and stop threshold), a Stoppage Reason template (the reasons operators will choose from, up to four levels deep under nine standard headings: Breakdown, Changeover, Cleaning, No Production, People, Planned Maintenance, Quality, Reboot and Waiting) and an Operator template (who will use the terminal, each with their own PIN), plus your shift and break times. The reasons no sensor could detect, waiting for a forklift, a pallet shortage, a shared compressor down, belong in that tree; recording them at the terminal is how one sensor yields a complete picture. Then four steps, none of which touch your control system:

• Mount the terminal where the operator works, on a wall or a line-side stand, and have your electrician connect it: a 220 V supply on its own 2 A breaker so the unit can be isolated, and the network by Cat 5 Ethernet to your access point (DHCP by default, or a fixed IP if you prefer), or the Augos 4G router if one was supplied. Your IT team allows the terminal to reach the Augos platform and a time server through the firewall; we send the allow-list with the kit. Everything arrives in one box: the terminal, three compression glands, and the photoelectric sensor with its cable, bracket and reflector.
• Mount the sensor onto the line, at the bottleneck, and wire it into one of the terminal's pulse inputs. The standard sensor is a polarised retroreflective photoelectric sensor that suits most lines; proximity or rotational sensors, or a sensor you already own with a PNP output, work too. It counts product as it passes; nothing is tapped into your PLC.
• We load your rules. Augos sets the platform up from our end using the three templates: your products and line settings, your stoppage reasons, and the people who'll use it, operators, managers and users, each with the right access. The rules go to the terminal over the air, so this step can run while the hardware is still being mounted.
• It syncs and starts measuring. Four checks close the installation: the terminal powers up without errors, the network diagnostic on the terminal passes, the sensor counts passing product, and every cable is secured and glanded. From there, configuration and firmware are pushed from the platform, so there's nothing to maintain on site.

Training and support, included

You're not left to work it out. Training and go-live take two days, and Augos stays on hand afterwards:

• Management and users are trained on reading the reports: what each one answers, how to drill into a loss, and how to run a review straight off the numbers.
• Operators are trained on the terminal itself, classifying a stop, calling for help and keeping the data clean, because the accountability layer only works if they actually use it. The interface is built to be learnt quickly; training usually takes one or two shifts, after which the line runs on its own.
• Ongoing support is remote and continuous: diagnostics, configuration changes, new products or lines, and firmware updates, all handled from our end without a site visit.

One line or every region

The same setup rolls out across lines, sites and regions the same way, so a single-line pilot and a multi-site rollout are the same job at different scale.

Resilient by design

The Augos Operator Terminal keeps measuring at full resolution when the network drops. Every count and every stop is stored on the unit and the backlog syncs when the connection returns, so a network fault never becomes a gap in the record. Configuration and firmware arrive over the air in the same way, which is why nothing on site needs a technician's visit to maintain.